Electrical device protective housing

ABSTRACT

Protective housings for an electrical device, such as a switches or receptacle, and methods for installing protective housings are disclosed. A protective housing for an electrical device includes a baseplate with an internal opening and first arcuate cutout along the internal opening. The protective housing also includes a first insert with a second arcuate cutout and at least one aperture. The first insert fits within the opening. The first and second arcuate cutouts form a through hole when the first insert is fitted within the opening.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. 119(e)(1) toprovisional U.S. Patent Application Ser. No. 61/975,943, filed Apr. 7,2014, the disclosure of which is incorporated by reference herein.

FIELD

This application relates to a protective housing for an electricaldevice such as a switch or receptacle and a method for its attachment.

BACKGROUND

An electrical device such as a switch or receptacle may be mounted to astructure, such as a house. Later, it may be desired to add a protectivehousing to protect or otherwise prevent access to the components of theswitch or receptacle. Traditional protective housings require thecomplete removal of mounting screws prior to installation, which mayfurther require unmounting the electrical device. Traditional protectivehousing installation may require co-installation of the protectivedevice with the electrical device.

To address this problem, keyhole-type protective housings have beendeveloped. Keyhole-type protective housings can be installed onalready-mounted electrical devices due to their inclusion of at leastone keyhole—a through hole with a large end to be placed over the headof an already-inserted mounting screw and a small end to be subsequentlypositioned under the screw head by laterally sliding the housing.However, keyhole-type protective housings have several disadvantages.First, if the head an already-inserted mounting screw is larger than thelarge end of the keyhole, the mounting screw would still need to becompletely removed prior to installation.

Second, because a keyhole-type protective housing can move laterallyalong the keyhole, the user must take care to align the housing beforetightening the mounting screws. The user often has to repeat thisprocess until he is satisfied that the housing is level and plumb.

Third, keyhole-type products are out of compliance with NationalElectrical Code (NEC) and Underwriters' Laboratory (UL) standardsbecause the keyholes comprise large diameter areas into which a childcan insert their fingers or metallic objects, risking electrical shock.Further, water can seep into the large diameter areas if the housing lidis compromised, which is of concern because electrical devices withprotective housings are often installed into areas exposed to rain orirrigation systems.

Fourth, because keyhole-type protective housings require the user toslide the faceplate in a plane parallel with the front of the electricaldevice, any sealing gaskets attached to the rear of keyhole-typeprotective housing can suffer significant abrasion from the surfacetexture of the surrounding wall (e.g., brick or stucco) or on sharpedges for the electrical mounting box during installation. And, if thegasket is torn or compromised by this abrasion, water can seep into theelectrical device and create a shock hazard or short.

An additional issue is size- and electrical device-specific productmatching. Electrical devices requiring protection may be of a variety oftypes, including ground-fault circuit interrupter (GFCI) outlets, duplexoutlets, 220V outlets, and toggle switches; may be sized as 1-gang,2-gang, 3-gang, 4-gang or larger; and may include multiple outlet orswitch types. Traditional and key-hole protective housings arespecifically matched to a particular electrical device size and typeconfiguration—and sometimes matched to a specific electrical deviceversion, even including particular mounting screws. This can limit theend user's ability to efficiently acquire a suitable protective housingfor a switch or receptacle when that electrical device does not come asa kit with a protective device.

SUMMARY

Devices and methods disclosed herein overcome some or all of the abovedisadvantages and improve the art by way of a providing an improvedprotective housing, sometimes including a weatherproof cover or otherlid.

In one embodiment, a protective housing for an electrical deviceincludes a baseplate with an internal opening and first arcuate cutoutalong the internal opening. The protective housing also includes a firstinsert with a second arcuate cutout and at least one aperture. The firstinsert fits within the opening. The first and second arcuate cutoutsform a through hole when the first insert is fitted within the opening.

In another embodiment, a protective housing includes a baseplate with afirst arcuate cutout and an insert with a second arcuate cutout. Theprotective housing is formed when the baseplate and the insert areassembled. The protective housing provides a protective barrier toprevent accidental electrical shocks when the protective housing ismounted to an electrical device. The first and second arcuate cutoutsalign together to form a through hole that can to receive a first screw.

In yet another embodiment, a protective housing can be formed over anelectrical device by placing a baseplate over the electrical device,aligning a first arcuate cutout on the baseplate with a mounting screwon the electrical device, providing an insert with a second arcuatecutout, aligning the second arcuate cutout of the insert with the firstarcuate cutout and the mounting screw, positioning the insert againstthe baseplate, and tightening the mounting screw.

In yet another embodiment, a protective housing kit for an electricaldevice includes a baseplate, a lid, a first hinge pin, and a secondhinge pin. The baseplate includes a first baseplate hinge component on afirst baseplate side and a second baseplate hinge component on a secondbaseplate side. The lid includes a first lid hinge component on a firstlid side and a second lid hinge component on a second lid side. Thefirst hinge pin has a first structural feature and the second hinge pinhas a second structural feature distinct from the first structuralfeature. The first baseplate hinge component, the first lid hingecomponent, and the first hinge pin can be assembled into a first hingethat rotatably connects the baseplate and the lid. The second baseplatehinge component, the second lid hinge component, and the second hingepin can be assembled into a second hinge that rotatably connects thebaseplate and the lid.

Additional objects and advantages will be set forth in part in thedescription which follows, and in part will be obvious from thedescription, or may be learned by practice of the disclosure. Theobjects and advantages will also be realized and attained by means ofthe elements and combinations particularly pointed out in the appendedclaims. It is to be understood that both the foregoing generaldescription and the following detailed description are exemplary andexplanatory only and are not restrictive of the claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B are views of a protective housing.

FIGS. 2A-2E are views of a baseplate.

FIGS. 3A-3B are views of a duplex insert.

FIGS. 3C-3D are views of a duplex insert with handle.

FIG. 3E is a view of a GFCI insert with handle.

FIGS. 4A-4C are views of a gasket.

FIGS. 5A-5D are views of a lid.

FIGS. 6A-6D are views of a plug for a baseplate gap.

FIG. 7A is a view of a protective housing including an attached lid.

FIGS. 7B-7C are views of a hinge pin.

FIGS. 8A-8C illustrate an alternative baseplate and lid combination,including hinge assemblies.

FIGS. 9A-9C illustrate another alternative baseplate and lidcombination, including hinge assemblies.

FIGS. 10A-10C illustrate another alternative baseplate and lidcombination, including hinge assemblies.

FIGS. 11A-11E illustrate another alternative baseplate and lidcombination, including hinge assemblies.

FIGS. 12A-12C illustrate another alternative baseplate and lidcombination, including hinge assemblies.

FIG. 13 is a view of a form-fitting seal for a through hole.

FIG. 14 is a flow chart of a method of installing a protective housingincluding a lid.

FIGS. 15A-15B are views of a protective housing with a 220V insert.

FIGS. 15C-15E are views of a 220V insert.

FIGS. 16A-16B are views of a protective housing with a double GFCIinsert.

FIGS. 17A-17B are views of a protective housing with a GFCI insert and aduplex insert.

FIGS. 18A-18D are views of a 2-gang baseplate.

FIGS. 19A-19C are views of a 2-gang gasket.

FIGS. 20A-20D are views of a 2-gang lid.

DETAILED DESCRIPTION

Reference will now be made in detail to the examples, which areillustrated in the accompanying drawings. Wherever possible, the samereference numbers will be used throughout the drawings to refer to thesame or like parts. Directional references such as “top,” “horizontal,”and “vertical” are for ease of reference to the figures. Although thedrawings show a weatherproof-type cover or “hood,” it should beunderstood that the method and attachment device is not so limited. Thedevices and methods are applicable for the attachment of a protectivehousing with or without an attached lid, such as a face plate,weatherproof cover, or other protective plate to an electrical devicesuch as a switch or receptacle.

FIGS. 1A and 1B provide a front and back view, respectively, of aprotective housing 1 comprising a baseplate 10 and an insert 40.Protective housing 1 can be installed upon an electrical device, such asan electrical outlet or toggle switch, and can further include aweatherproof lid 60, as depicted, for example, in FIG. 7A. Wheninstalled, the housing provides a protective barrier to preventaccidental electrical shocks to the user and further protects theelectrical device from water, dirt, or debris.

As shown in FIGS. 1A and 1B, baseplate 10 can include a generally flatportion 14 and walls 13 formed at the perimeter of the flat portion 14.The walls 13 for protective housing 1 can include a vertical baseplatehinge component 21 on a vertical side 11 of protective housing 1, whichis shown the shorter side in the figures, and a horizontal baseplatehinge component 22 on a horizontal side 12 of protective housing 1,which is shown the longer side in the figures. As noted, the terms“vertical” and “horizontal” are used for ease of reference to thefigures, and the person of skill in the art would understand thatprotective housing 1 can be mounted on an electrical device at anyangle. For example, vertical side 11 can be positioned horizontally andhorizontal side 12 can be positioned vertically. Moreover, baseplatehinge components 21 and 22 can each include multiple portions, as shown,for example, in FIGS. 1A-2E.

FIGS. 2A-2E provide front, back, perspective, horizontal side, andvertical side views, respectively, of baseplate 10 without insert 40.Baseplate flat portion 14 comprises include an internal opening 36,which is configured to fit and receive insert 40. The perimeter ofinternal opening 36 includes one or more baseplate arcuate cutouts 15.Preferably, a recessed area 15A borders each baseplate arcuate cutout15. When insert 40 is installed into baseplate 10, one or more centralthrough holes 18 and/or side through holes 17 are formed by thealignment of corresponding baseplate arcuate cutouts 15 and insertarcuate cutouts 45. Through holes 18 and 17 are configured to receive ascrew and can be used to secure the protective housing to the electricaldevice.

In a typical use of protective housing 1, approximately half of thethrough holes will be filled with mounting screws. Thus, protectivehousing 1 may include one or more form-fitting seals 91 to fill throughholes unoccupied by mounting screws after assembly, thereby providingadditional protection to the electrical device. FIG. 13 depicts seal 91,which is preferably is made of rubber or plastic and includes a shaft 92and two rims 93 and 94 on each side of the shaft. In one embodiment,seal 91 is symmetrical in design such that rims 93 and 94 are identical.

The perimeter of internal opening 36 may further include a steppedportion 16 to mate with a corresponding stepped portion 46 of insert 40,preferably on the front of baseplate flat portion 14. And in oneembodiment, stepped portion 16 includes baseplate arcuate cutoutrecessed areas 15A.

Baseplate flat portion 14 can include one or more baseplate snapelements 19 to engage with corresponding insert snap elements 49 ofinsert 40. Additionally, baseplate flat portion 14 can include one ormore integral baseplate through holes 35, which can be used to securethe protective housing to the electrical device. Preferably, a recessedarea 35A surrounds each integral baseplate through hole 35.

Baseplate 10 can further include baseplate lock hole 38 and/or baseplateclosure mechanism 39 on walls 13, preferably on the wall portionopposite from horizontal baseplate hinge component 22. If lid 60 isincluded in protective housing 1, as depicted, for example in FIG. 7A,baseplate closure mechanism 39 can engage with lid closure mechanism 39to temporarily seal protective housing 1 when lid 60 is closed, furtherprotecting enclosed electrical devices from the elements. Baseplate lockhole 38 aligns with lid lock hole 68 when lid 60 is closed, providingthe opportunity to lock the protective housing using a standardcombination or key lock. Baseplate lock hole 38 and/or baseplate closuremechanism 39 can be formed integrally with walls 13 or can be attachedthereto.

Gasket 95 can be positioned against or adhered to gasket receivingsurface 96 on backside of baseplate 10, shown in FIGS. 1B and 2B, tocreate or improve the seal between the baseplate 10 and a wall orstructure surrounding the electrical device when protective housing 1 isinstalled. FIGS. 4A-4C illustrate perspective, front and vertical sideviews, respectively, of an exemplary gasket 95. Insert 40 includes atleast one aperture 47, which is configured to receive a particular typeof electrical device, and one or more insert arcuate cutouts 45 on itsouter perimeter. Preferably, a recessed area 45A borders each insertarcuate cutout 45. As noted above, insert 40 can include one or moreinsert snap elements 49 to engage with baseplate snap elements 19. Snapelements 19 and 49 can include spring-type snap elements, shelf-typesnap elements, and/or any other type of snap elements known in the art,provided that each corresponding baseplate snap element 19 and insertsnap element 49 are configured to engage with one another.

In order to accommodate a wide array of electrical devices, multipletypes of inserts 40 with different apertures are contemplated. Forexample, insert 40 depicted in FIGS. 1A-1B is a GFCI insert 41, whichcontains a single aperture 47 sized to accommodate a GFCI outlet. FIG.3E is an illustration of GFCI insert 41 that has not been installed in abaseplate 10. GFCI insert 41 depicted in FIG. 3E further includes ahandle 50, which can be included in insert 40 to provide betterergonomic gripping of the insert during assembly or disassembly ofprotective housing 1.

As another example, FIGS. 3A-3B depict front and back sides,respectively, of duplex insert 42, which is a type of insert 40 with twoapertures to accommodate a standard duplex outlet. And, FIGS. 3C-3Ddepict perspective front and back sides, of an alternative duplex insert42 that further includes handle 50. Duplex insert 42 can further includeintegral insert through hole 48, which can be used to further secureinsert 40 to the electrical device. Preferably, a recessed area 48Asurrounds each integral insert through hole 48.

The GFCI and duplex insert embodiments disclosed herein are exemplary.It is contemplated that other inserts 40 may include alternativeaperture configurations to accommodate switches, such as toggle switchesand dimmer switches, and various other electrical outlets known in theart. In another embodiment, insert 40 can include breakout lines toallow custom apertures to be selected and created, thus providingadditional flexibility in accommodating a variety of electrical devicesduring installation of protective housing 1.

As depicted in FIGS. 3B and 3D, the backside of insert 40 can include astepped portion 46 along its outer perimeter. Stepped portion 46 isconfigured to mate with corresponding stepped portion 16 on the front ofbaseplate 10. During installation of such embodiments of protectivehousing 1, insert 40 is positioned on top of the front of baseplate 10.In alternative embodiments, stepped portion 46 can be located on thefront of insert 40 and stepped portion 16 can be located on the back ofbaseplate 10, such that insert 40 would be positioned behind the back ofbaseplate 10 during installation.

FIGS. 5A-5D provide perspective, horizontal side, front, and verticalside views, respectively, of lid 60. Horizontal side 12 of lid 60 caninclude a horizontal lid hinge component 62 configured to correspondwith horizontal baseplate hinge component 22. As depicted in FIG. 7A,when assembled with one or more hinge pins 70, horizontal lid hingecomponent 62 and horizontal baseplate hinge component 22 form a hinge 20that rotatably connects baseplate 10 and lid 60 on horizontal side 12.FIGS. 7B and 7C depict further detail of an embodiment of hinge pin 70.Similarly, vertical side 11 of lid 60 can include a vertical lid hingecomponent 61 configured to correspond with vertical baseplate hingecomponent 21. When assembled with one or more hinge pins 70, verticallid hinge component 61 and vertical baseplate hinge component 21 form ahinge 20 that rotatably connects baseplate 10 and lid 60 on verticalside 11.

Preferably, horizontal lid hinge component 62 and horizontal baseplatehinge component 22 are positioned along baseplate 10 and lid 60,respectively, to include clearances such that the horizontal hingecomponents 22 and 62 do not touch or otherwise interfere with therotation of lid 60 about an assembled vertical hinge 20. And,preferably, vertical lid hinge component 61 and vertical baseplate hingecomponent 21 are positioned on baseplate 10 and lid 60, respectively, toinclude clearances such that the vertical hinge components 21 and 61 donot touch or otherwise interfere with the rotation of lid 60 about anassembled horizontal hinge 20.

In one embodiment, the hinge pins are configured lock into appropriatelid and baseplate hinge components using interference fit, detents,living hinge snap features, threads, or other locking features to formhinge 20. It is also contemplated that a hinge pin can include a caphead at one hinge pin to prevent the pin from passing through the lidand baseplate hinge components. Such features can prevent the accidentaldisconnection of a hinge pin from the baseplate hinge component and thelid hinge component of an assembled hinge. As shown in FIGS. 5C and 5D,Lid 60 can further include lid lock hole 68 and/or lid closure mechanism69, preferably on the wall portion opposite from horizontal lid hingecomponent 62.

FIGS. 8A-11E illustrate alternate configurations for attaching lid 60 tobaseplate 10 via a hinge, wherein hinge pins are configured to be usedonly in hinge assemblies on a particular side of the protective housing.

FIGS. 8A-8C illustrate a lid attachment configuration wherein hinge pinsare not interchangeable due to a difference in diameter between hingepins. As shown FIG. 8A, baseplate 10 can include a larger diameterbaseplate hinge component 23 and lid 60 can include larger diameter lidhinge component 63. Larger diameter baseplate hinge component 23 andlarger diameter lid hinge component 63 correspond to one another and areconfigured to be assembled into larger diameter hinge 26 by theinsertion of larger diameter pin 73 into the recesses of hingecomponents 23 and 63, as shown in FIG. 8C. Although FIGS. 8A-8Cillustrate larger diameter baseplate hinge component 23 as horizontalbaseplate hinge component 22 and larger diameter lid hinge component 63as horizontal lid hinge component 62, the larger diameter components 23and 63 can alternatively be positioned on vertical side 11 of theprotective housing 1.

Also as shown FIG. 8A, baseplate 10 can include a smaller diameterbaseplate hinge component 24 and lid 60 can include smaller diameter lidhinge component 64. Smaller diameter baseplate hinge component 24 andsmaller diameter lid hinge component 64 correspond and are configured tobe assembled into smaller diameter hinge 25 by the insertion of smallerdiameter pin 74 into the recesses of hinge components 24 and 64, asshown in FIG. 8B. Although FIGS. 8A-8C depict smaller diameter baseplatehinge component 24 as vertical baseplate hinge component 21 and smallerdiameter lid hinge component 64 as vertical lid hinge component 61, thesmaller diameter components 24 and 64 can alternatively be positioned onhorizontal side 12 of the protective housing 1.

Larger diameter hinge pin 73 cannot fit into the recesses of smallerdiameter hinge components 24 and/or 64, and therefore these elementscannot be assembled into a suitable hinge 20. Similarly, smallerdiameter hinge pin 74 can only be loosely inserted into the recesses oflarger diameter hinge components 23 and 63, and therefore these elementscannot be assembled into a suitable hinge 20. Further, if smallerdiameter hinge pin 74 has locking features to engage with correspondinglocking features in smaller diameter components 24 and/or 64, suchfeatures are unlikely to engage with locking features in larger diametercomponents 23 and 63. Thus, a working hinge 20 cannot be assembled if aninappropriate diameter pin is used.

Consistent with FIGS. 8A-8C, a protective housing kit can includebaseplate 10, lid 60, larger diameter hinge pin 73, and smaller diameterhinge pin 74. Thus, during installation of protective housing 1, theuser can elect to assemble smaller diameter hinge 25 and discard largerdiameter hinge pin 73, as in FIG. 8B; or elect to assemble largerdiameter hinge 26 and discard smaller diameter hinge pin 74, as in FIG.8C.

FIGS. 9A-9C depict a hinge configuration similar to that of FIGS. 8A-8C,but in this embodiment larger diameter hinge 26 includes two largerdiameter sub-hinges 26B and assembled smaller diameter hinge 25 includestwo smaller diameter sub-hinges 25B. As shown in FIGS. 9A and 9C, largerdiameter hinge 26 can include two larger diameter pins 73, and bothlarger diameter baseplate hinge component 23 and larger diameter lidhinge component 63 can include additional parts. For example, as shown,larger diameter baseplate hinge component 23 includes two parts andlarger diameter lid hinge component 63 includes four parts. Similarly,as shown in FIGS. 9A and 9B, smaller diameter hinge 25 can include twosmaller diameter pins 74, and both smaller diameter baseplate hingecomponent 24 and smaller diameter lid hinge component 64 can includeadditional parts. For example, as shown, smaller diameter baseplatehinge component 24 includes two parts and smaller diameter lid hingecomponent 64 includes four parts. Consistent with FIGS. 9A-9C, aprotective housing kit can include baseplate 10, lid 60, two largerdiameter hinge pins 73, and two smaller diameter hinge pin 74.

In another embodiment, protective housing 1 can be configured such thatlarger diameter hinge 26 can be assembled with more than two largerdiameter sub-hinges 26B and/or smaller diameter hinge 25 can beassembled with more than two smaller diameter sub-hinges 25B. In thisembodiment, a corresponding greater number of larger diameter hinge pins73 and smaller diameter hinge pins 74 may be included in a protectivehousing kit.

In yet aother embodiment, protective housing 1 can be configured toinclude multiple sub-hinges, and not all sub-hinges on the respectivevertical 11 and horizontal 12 sides of the protective housing wouldrequire a side-specific pin for assembly. In this embodiment, somesub-hinges on each side can be assembled using a generic hinge pin thatis not side-specific. That is, only a portion of the sub-hinges can beconfigured to accommodate a pin with a side-specific diameter.

FIGS. 10A-10C illustrate a lid attachment configuration wherein hingepins are not interchangeable due to a difference in length between hingepins. As shown in FIG. 10A, baseplate 10 can include a longer baseplatehinge component 22A and lid 60 can include longer lid hinge component62A. Longer baseplate hinge component 22A and longer lid hinge component62A correspond to one another and are configured to be assembled intolonger hinge 26A by the insertion of longer pin 71 into the recesses ofhinge components 22A and 62A, as shown in FIG. 100. Longer pin 71 is oflength 71A, and the parts of hinge components 22A and 62A are sized andspaced to cumulatively approximate length 71A. FIGS. 10A-10C depictlonger baseplate hinge component 22A as horizontal baseplate hingecomponent 22 and longer lid hinge component 62A as horizontal lid hingecomponent 62, but the longer components 22A and 62A can alternatively bepositioned on vertical side 11 of the protective housing 1.

Also as shown FIG. 10A, baseplate 10 can include a shorter baseplatehinge component 21A and lid 60 can include shorter lid hinge component61A. Shorter baseplate hinge component 21A and shorter lid hingecomponent 61A correspond and are configured to be assembled into shorterhinge 25A by the insertion of shorter pin 72 into the recesses of hingecomponents 21A and 61A, as shown in FIG. 10B. Shorter pin 72 is oflength 72A, and the parts of hinge components 21A and 61A are sized andspaced to cumulatively approximate length 72A. FIGS. 10A-10C depictshorter baseplate hinge component 21A as vertical baseplate hingecomponent 21 and shorter lid hinge component 61A as vertical lid hingecomponent 61, but the shorter components 21A and 61A can alternativelybe positioned on horizontal side 12 of the protective housing 1.

Because shorter hinge pin 72 is significantly shorter than length 71A,shorter hinge pin 72 cannot fully occupy the recesses of longer hingecomponents 22A and 62A. Therefore, these elements-22A, 61A, and71—cannot be assembled into a suitable hinge 20. Similarly, becauselonger hinge pin 71 is significantly longer than length 72A, wheninserted into the recesses of shorter hinge components 21A and 61A,longer hinge pin 71 would extend significantly beyond hinge components21A and 61A. Such an assembled hinge, even if assembly is possible, isdisfavored. Thus, a user assembling the hinge configurations of FIGS.10A-10C would understand which of shorter pin 72 or longer pin 71 to usedepending on whether shorter hinge 25A or longer hinge 26A is desired tobe assembled.

Consistent with FIGS. 10A-100, a protective housing kit can includebaseplate 10, lid 60, longer hinge pin 71, and shorter hinge pin 72.Thus, during installation of protective housing 1, the user can elect toassemble short hinge 25A and discard longer hinge pin 71, as in FIG.10B; or elect to assemble short hinge 26A and discard shorter hinge pin72, as in FIG. 100.

FIGS. 11A-11E illustrate a lid attachment configuration wherein hingepins are not interchangeable due to a difference in shape of the headsof hinge pins. As shown FIG. 11A, baseplate 10 can include a firstbaseplate hinge component 27A and lid 60 can include first shaped lidhinge component 65. One part of first lid hinge component 65 can includea first shaped head receiving portion 65A. First baseplate hingecomponent 27A and first shaped lid hinge component 65 correspond to oneanother and are configured to be assembled into first shaped hinge 27 bythe insertion of first shaped pin 77 into the recesses of hingecomponents 27A and 65, as shown in FIG. 11B. First shaped hinge pin 77is generally cylindrical but includes a first shaped head 77A. As shownin FIG. 11D, first shaped head 77A is configured to snugly fit intoshaped head receiving portion 65A of first shaped lid hinge component 65when first shaped hinge 27 is assembled.

Also as shown FIG. 11A, baseplate 10 can include a second baseplatehinge component 28A and lid 60 can include second shaped lid hingecomponent 66. One part of second lid hinge component 66 can include ashaped head receiving portion 66A. Second baseplate hinge component 28Aand second shaped lid hinge component 66 correspond to one another andare configured to be assembled into second shaped hinge 28 by theinsertion of second shaped pin 78 into the recesses of hinge components28A and 66, as shown in FIG. 11C. Second shaped hinge pin 78 isgenerally cylindrical but includes a first shaped head 78A. As shown inFIG. 11E, second shaped head 78A is configured to snugly fit into shapedhead receiving portion 66A of second lid hinge component 66 when secondshaped hinge 28 is assembled.

First shaped head 77A cannot fit into shaped head receiving portion 66Aof second lid hinge component 66. And, second shaped head 78A cannot fitinto shaped head receiving portion 65A of first shaped lid hingecomponent 65. Moreover, the snug fit between the shaped pin heads 77Aand 78A and shaped head receiving portions 66A and 66B, respectively,can serve to further secure a shaped pin within an assembled hinge. Theshapes of first shaped head 77A and second shaped head 78A depicted inthe figures are illustrative and not limited to the cross-sectionalsquare and star shapes shown. For example, a shaped pin head 77A or 78Amay have a triangular, rectangular, other polygonal, oval-shaped, orirregularly-shaped cross section. Alternatively, the lid configurationcan include a cylindrical pin without a shaped head in lieu of one ofthe shaped pins. Further in some embodiments, baseplate hinge components27A and 28A may be identical.

Consistent with FIGS. 11A-11E, a protective housing kit can includebaseplate 10, lid 60, a first shaped pin 77, and a second shaped pin 78.Thus, during installation of protective housing 1, the user can elect toassemble first shaped hinge 27 and discard second shaped pin 78, as inFIGS. 11B and 11D; or elect to assemble second shaped hinge 28 anddiscard first shaped pin 77, as in FIGS. 11C and 11E.

Various combinations of the above described hinge configurations canalso be used. That is, first and second pins can differ based on one ormore structural features, including one or more of different lengths,different diameters, and differently shaped heads; baseplate and lidhinge components would correspond to such structural feature(s).

Further, the configurations depicted in FIGS. 8A-11E depict lid hingecomponent parts (e.g., 63, 64, 61A, 62A, 65, 66) surrounding to eachbaseplate hinge component (e.g., 23, 24, 21A, 22A, 27A, 28A) (or partsthereof) along assembled hinges (or sub-hinges). However, it iscontemplated that the configurations of lid hinge component parts andbaseplate component parts can be reversed such that each lid hingecomponent (or part thereof) would be surrounded by correspondingbaseplate component parts along assembled hinges (or sub-hinges). Forexample, In the case of a hinge configuration where the placement of thebaseplate hinge component and the lid hinge component were reversed, theshaped head receiving portions 65A and 66A and would be included infirst and second baseplate hinge components 27A and 28A instead of thelid hinge components 65 and 66.

FIGS. 12A-12C depict a configuration similar to that shown in FIGS.9A-9C, but includes baseplate with shorter walls 10A and a flatter lid60A. In this embodiment, protective housing has a smaller profile andcan be used where more inconspicuous protection of an electrical deviceis desired.

In order to provide a place for the electrical cords of a plugged-inelectrical apparatus to exit a protective housing 1 installed on anelectrical outlet while lid 60 remains closed, baseplate 10 can includeone or more gaps 30 in walls 13 located opposite from baseplate flatportion 14. As depicted in FIGS. 1A-2C, protective housing 1 preferablyincludes two gaps 30, one on the wall portion opposite from verticalbaseplate hinge component 21 and another on the wall portion oppositefrom horizontal baseplate hinge component 22. This configuration permitselectrical cords to exit an installed protective housing 1 at a pointclosest to the ground, regardless of whether the protective housing isinstalled horizontally or vertically. The plug gap 30 that is not beinguse can be filled with plug 31, further protecting the electrical outletfrom external elements, such as water, dirt, and debris. Or, if desired,both plug gaps 30 can be filled with plugs 31. Plugs 31 can beconsidered part of protective housing 1.

FIGS. 6A-6D provide views of plug 31. Plug 31 can be installed into pluggap 30 by sliding plug projections 34 into gap grooves 37 of gap 30until plug snap element 32 engages with gap snap element 33 in gap 30.In one embodiment, plug 31 can be removed after its insertion bypressing on the side of plug 31 containing plug snap element 32 untilgap snap element 33 is disengaged; then, plug 31 can be pulled fromprotective housing 1.

A protective housing 1 based on baseplate 10 illustrated in FIGS. 1A-2E,can protect electrical devices that are 1-gang in size. However, asdiscussed below, with respect to FIGS. 15A-20D, a multi-gang protectivehousing 101 can protect electrical devices that are 2-gang, 3-gang,4-gang or more in size. Multi-gang protective housing 101 containssubstantially the same elements as 1-gang protective housing 1, but caninclude multiple inserts 40 and/or larger inserts 140 to accommodateaperture 37 requirements of multi-gang electrical devices. The insertsand insert combination discussed below are exemplary and not limiting.

FIG. 15A depicts a 2-gang protective housing 101 including 2-gangbaseplate 110 and 220V insert 143, which is a type of larger insert 140.FIG. 15B is an exploded view of the 2-gang protective housing of FIG.15A. This embodiment of 2-gang protective housing 101 includes baseplatehinge components 221 only on a single side, and includes only a singlegap 30 on the wall 13 opposite from hinge components 221. FIGS. 15C-15Eprovide top, front, and side views, respectively, of an alternative 220Vinsert 143. Each larger insert 140 can contain similar elements asinsert 40, including, insert arcuate cutouts 45 and at least oneaperture 47, as well as recessed areas 45A, insert snap elements 49, andstepped portion 46. Insert 140 can further include breakout lines 144.For example, as shown, 220V insert 143 can include breakout lines 144 toaccommodate various sized 220V and/or RV-type electrical receptacles,including those with standard diameter sizes promulgated by the NationalElectrical Manufacturers Association (NEMA). To increase the size of the220V receptacle aperture 47, portions of insert 143 internal to therespective break-out rings 144 can be removed prior to or during theprocess of installing protective housing 101.

FIG. 16A depicts a 2-gang protective housing 101 including a 2-gangbaseplate 110 and a double GFCI insert 141, which is a type of largerinsert 140. Double GFCI insert 141 includes two GFCI apertures 47 formounting on an electrical device comprising two adjacent GFCI outlets.FIG. 16B is an exploded view of the 2-gang protective housing of FIG.16A.

FIG. 17A depicts a 2-gang protective housing 101 including a 2-gangbaseplate 110, a single GFCI insert 41, and a single duplex insert 42.Multi-gang baseplate 110 can fit multiple inserts 40 of the same ordifferent types, which provides for flexibility when installingmulti-gang protective housing 101 on a multi-gang electric device. Assuch, modular assembly of the protective housing is disclosed. By usingdifferent inserts 40, customized multi-gang protective housing 101 caneasily be installed. The particular protective housing 101 depicted inFIG. 17A includes apertures 37 for mounting on an electrical devicecomprising a GFCI outlet adjacent to a duplex outlet. FIG. 17B is anexploded view of the 2-gang protective housing of FIG. 17A.

FIGS. 18A-18D provide perspective, top, hinge component side, and frontviews, respectively, of an alternative embodiment of 2-gang baseplate110. In this embodiment, baseplate 110 includes two gaps 30 on the wall13 opposite from the wall 13 portion with baseplate hinge components221. Baseplate closure mechanism 39 is located on the same wall 13portion between the gaps 30.

Baseplate bar 111 bisects internal opening 36. Preferably, the frontsurface of baseplate bar 111 is at approximately the same level asbaseplate stepped portion 16. If, for example, two single inserts 40 areinstalled in this embodiment of 2-gang baseplate 110, one side of thestepped portion 46 of each of the inserts 40 can engage with baseplatebar 111. Thus, the baseplate bar 111 can support the inserts 40 in amanner similar to baseplate stepped portion 16, improve the seal betweenthe inserts 40 and baseplate 110, and ease installation, Baseplate bar111 can also be removable such that a user can pop it out duringinstallation if, for example, a 220V insert 143 is to be installed inprotective housing 101.

FIGS. 19A-19C illustrate perspective, front, and vertical side views,respectively, of an exemplary 2-gang gasket 195. Similar to gasket 95,gasket 195 can be positioned against or adhered to a gasket-receivingsurface on backside of baseplate 110, to create or improve the sealbetween the baseplate 110 and a wall or structure surrounding theelectrical device when protective housing 101 is installed.

FIGS. 20A-20D provide perspective, top, front, and hinge component sideviews, respectively, of 2-gang lid 160. 2-gang lid 160 containssubstantially the same elements as lid 60, but is configured tocorrespond with 2-gang baseplate 110, as depicted in FIGS. 18A-18D,instead of baseplate 10. The depicted embodiment of 2-gang lid 160includes only a single baseplate hinge component 161, but additionalbaseplate hinge components can be included. A multi-gang lid 160 may berotatably connected to a multi-gang baseplate 110 through the varioushinge assemblies discussed herein or in any other way known in the art.

FIG. 14 is a flow chart providing an exemplary method of installingprotective housing 1 or 101 on an electrical device. As in step S1, agasket 95 or 195 may optionally be adhered to or positioned upon thegasket receiving surface 96 on backside of baseplate 10 or 110.

As in step S2, baseplate 10 or 110 may be placed over the electricaldevice, such that the electrical device is positioned within theinternal opening 36 of baseplate 10 or 110. Prior to placing thebaseplate 10 or 110 upon the electrical device, one or more mountingscrews may already be inserted into the electrical device in order toaffix the electrical device to a support structure and/or to easeinstallation of protective housing 1 or 101.

As in step S3, the already-inserted mounting screw(s) are aligned withcorresponding baseplate arcuate cutout(s) 15. Properly alignment of thebaseplate arcuate cutout(s) 15 with the already-inserted mountingscrew(s) should ultimately result in a proper and aesthetically pleasingalignment of the baseplate 10 or 110 with the electrical device.

As in step S4, appropriate insert(s) 40 or 140 with an aperture(s) 47corresponding to the electrical device are provided. Optionally, and ifappropriate to form appropriately sized aperture(s) 47, portions of theinsert(s) 40 or 140 can be removed along break out lines 144.

As in step S5, insert arcuate cutout(s) 45 are aligned with thebaseplate arcuate cutout(s) 15 and the mounting screw(s). In thismanner, baseplate arcuate cutout(s) 15 and insert arcuate cutout(s) 45form a through hole around the already-inserted mounting screw(s). Thearcuate cutouts 14 and 45 allow the protective housing to be assembledupon an electrical device with partially inserted mounting screws,obviating the need for a user to remove the mounting screws beforeinstallation, even if the screw heads are larger than anticipated. Thisimproves both the speed and ease of installation—as well as anysubsequent removal of the protective housing.

If included in insert(s) 40 or 140, a handle 50 can be beneficially usedto manipulate the insert(s) in order to place insert arcuate cutout(s)45 into the appropriate position(s). Preferably, if baseplate flatportion 14 includes shelf-type snap elements 19 on the same side ofinternal opening 36 as the baseplate arcuate cutout(s) 15 aligned withthe mounting screw(s), insert snap elements 49 can be preliminarilyengaged with the baseplate shelf-type snap elements 19 during this step.

As in step S6, insert(s) 40 or 140 are positioned against the baseplate10 or 110. Insert(s) 40 or 140 are fitted within internal opening 36 ofthe baseplate 10, and aperture(s) 47 are fitted around the appropriateportions of the electrical device. If included in insert 40, handle 50can be beneficially used to appropriately position the insert(s) 40 or140. Where the perimeter of baseplate internal opening 36 includesbaseplate stepped portion 16 and the external perimeter of insert 40includes insert stepped portion 46, the respective stepped portions 16and 46 are mated together, assuring rigid alignment and improving theseal between the baseplate 10 or 110 and insert(s) 40 or 140.

As in step S7, where appropriate, corresponding baseplate snapelement(s) 19 and insert snap elements(s) 49 are snapped to each other,thereby attaching insert(s) 40 or 140 and baseplate 10 or 110.

As in step S8, the mounting screw(s) are tightened. Additional mountingscrews can be inserted into other through holes of protective housing 1and into the electrical device, and tightened. Tightening the mountingscrews compresses the protective housing 1 or 101 against the electricaldevice, and, where a gasket 95 or 195 is provided, compresses the gasketbetween the protective housing and the wall or structure upon whichelectrical device is mounted, to create a watertight seal. The integrityof the gasket is ensured because the gasket is attached via compressionand without potentially abrasive lateral sliding against the wall orstructure. Further, if stepped portions 16 and 46 are included in thebaseplate 10 or 110 and insert(s) 40 or 140, respectively, tighteningcertain mounting screw(s) compresses the baseplate 10 against the insert10, improving the seal and connection between the components. Where athrough hole includes recessed portion, a mounting screw can betightened until the head of the mounting screw is tightly pressedagainst the recessed portion. It may be noted that mounting screws arenot limited to any particular type of screw, but rather will beunderstood to include various types of attachments known in the art.

As in step S9, any through holes not occupied by a mounting screw can befilled with a form-fitting seal 91. To install seal 91, rim 93 ispositioned on top of the through hole and pressure is placed on rim 94until rim 93 is pushed through the through hole to the back theprotective housing and shaft 92 fills the through hole. The rim 94 willremain on the front side of the protective housing, preferable in arecessed portion of the through hole.

As in step S10, a lid 60 or 160 can be attached to baseplate 10 or 110.Where applicable, an appropriate protective housing side for the hinge20 may be selected. Then, hinge 40 may be assembled by insertingappropriate hinge pin(s) 70 into the corresponding baseplate and lidhinge components. Alternatively, the baseplate 10 or 110 and lid 60 or160 can be attached by assembling hinge 40 prior to step S2.

As in step S11, if desired and appropriate, gap(s) 30 can be filled withplug(s) 31.

Other implementations will be apparent to those skilled in the art fromconsideration of the specification and practice of the disclosure. Thevarious elements of the protective housing 1 disclosed herein can becomposed of metal and or plastic and can be manufactured by any chosenmethod, including, for example, injection molding, die casting,stamping, extrusion, and/or machining. It is intended that thespecification and examples be considered as exemplary only, with a truescope and spirit of the invention being indicated by the followingclaims.

What is claimed is:
 1. A protective housing for an electrical devicecomprising: a baseplate including an internal opening and firstsemi-circular cutout along the internal opening; and a first insert witha second semi-circular cutout and at least one aperture, wherein thefirst insert fits within the opening and the first and secondsemi-circular cutouts form a circular through hole when the first insertis fitted within the opening, wherein the circular through hole is not akeyhole, and wherein the second semi-circular cutout is disposed alongan edge of the first insert that is shorter than both an overall lengthand an overall width of the first insert.
 2. The protective housing ofclaim 1 wherein: the baseplate further comprises a first stepped portionon substantially all perimeter edges of the internal opening, and thefirst insert comprises a second stepped portion on substantially allouter perimeter edges configured to engage with the first steppedportion.
 3. The protective housing of claim 1, wherein: the first insertcomprises a first snap element, and the baseplate comprises a secondsnap element configured to engage with the first snap element to allowfor the snapping of the first insert into the baseplate.
 4. Theprotective housing of claim 1 wherein the at least one aperture is sizedto fit around the electrical device.
 5. The protective housing of claim4 wherein the electrical device is one of a duplex receptacle, a GFCIreceptacle, a 220-volt receptacle, an RV-type receptacle, or a toggleswitch.
 6. The protective housing of claim 4 wherein the first insertfurther comprises at least one breakout line, wherein breaking the atleast one breakout line alters the size of the at least one apertureupon removal.
 7. The protective housing of claim 4, wherein thebaseplate opening is configured to accept a plurality of inserts suchthat the protective housing may be assembled as 2-gang, 3-gang, or4-gang housing.
 8. The protective housing of claim 7, wherein the atleast one aperture includes a first aperture configured to fit a GFCIreceptacle and a second aperture configured to fit a GFCI receptacle. 9.The protective housing of claim 7, further comprising a second insertwith a second at least one aperture distinct from the at least oneaperture of the first insert.
 10. The protective housing of claim 1,wherein baseplate further comprises walls on a baseplate outer perimeterand a hinge element on the walls.
 11. The protective housing of claim 10wherein the walls further comprise at least one gap, the at least onegap configured to receive a plug.
 12. The protective housing of claim 1,wherein the first insert further comprises a handle to provide betterergonomic gripping of the insert during assembly or disassembly.
 13. Theprotective housing of claim 1, wherein the protective housing does notinclude any keyholes.
 14. A protective housing comprising: a baseplatewith a first semi-circular cutout; and an insert with a secondsemi-circular cutout, wherein a protective housing is formed when thebaseplate and the insert are assembled, wherein the housing provides aprotective barrier to prevent accidental electrical shocks when theprotective housing is mounted to an electrical device, wherein the firstand second semi-circular cutouts align together to form a circularthrough hole that can to receive a first screw, wherein the circularthrough hole is not a keyhole, and wherein the second semi-circularcutout is disposed along an edge of the first insert that is shorterthan both an overall length and an overall width of the first insert.15. The protective housing of claim 14, further comprising a first screwto affix the protective housing to the electrical device.
 16. Theprotective housing of claim 15, further comprising a gasket thatattaches to the baseplate, wherein the screw compresses the gasket tocreate a watertight seal.
 17. A method of forming a protective housingover an electrical device, comprising: placing a baseplate over theelectrical device; aligning a first semi-circular cutout on thebaseplate with the mounting screw on the electrical device; providing aninsert with a second semi-circular cutout; aligning the secondsemi-circular cutout of the insert with the first semi-circular cutoutand the mounting screw to form a circular through hole surrounding themounting screw, the circular through hole not being a keyhole;positioning the insert against the baseplate; and tightening themounting screw.
 18. The method of claim 17, further comprising snappingthe insert to the baseplate.
 19. The method of claim 18, furthercomprising placing a gasket behind the baseplate.
 20. The method ofclaim 17, further comprising inserting the mounting screw into theelectrical device prior to placing the baseplate over the electricaldevice.